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The integration of sustainable nanotechnology into aluminum composites offers significant potential for enhancing mechanical and tribological properties, particularly in energy-related applications. Aluminium alloys are extensively utilised in the aerospace and automotive industries. Due to its low density, superior mechanical characteristics, improved resistance to corrosion and wear, and lower thermal coefficient of expansion as compared to other metals and alloys, From a scientific and technological point of view, these materials are highly interesting applicants for a range of applications due to their good mechanical qualities and relatively low cost of manufacturing. Combining the advantageous qualities of metals and ceramics is the goal of producing metal matrix composite materials. The current research focuses on examining the behaviour of an aluminum cast alloy with a composite made of molybdenum disulphate using the stir casting method. Specimen obtained by the stir casting method were subjected to wear tests and hardness tests. The resultant composites demonstrated improved hardness and wear behavior, making them highly suitable for applications in energy sectors. This research emphasizes the role of sustainable nanotechnology in advancing aluminum-based materials for energy applications, contributing to both performance efficiency and environmental sustainability.

The enhanced specific strength of SiC Particulate Metal Matrix Composites (PMMC) has been the major contributing factor which helps to find applications in the aerospace and automotive industries. Uniform distribution of the particulates in PMMC controls the attainment of better mechanical properties. The most accepted method for producing such a composite is stir casting in which the homogeneity of particulate reinforcement is a significant challenge. This research work proposes a new method for mixing the particulate reinforcement with the liquid and semi-solid aluminium matrix to ensure a uniform mix of the particulates using a gyro shaker. Gyro shaker is a dual rotation mixer commonly used for mixing high viscous fluids. It rotates about two mutually perpendicular axes which help in thoroughly mixing of the ingredients. Developed Computational Fluid Dynamics (CFD) simulation model of the mixing device in finding the mixing performance while mixing SiC particulates with glycerol. The results of the simulation were also validated by experimentation. Analogue fluid simulation of gyro casting was carried out using water and glycerol/water mixture which are having a closer value of viscosity as that of liquid aluminium and semi-solid aluminium. The mixing time obtained in the water system at gyration speeds of 29.63 rpm, 58.18 rpm, 72.73 rpm and 87.27 rpm was 61.84 sec, 43.44 sec, 26.85 sec and 27.24 sec respectively. The mixing time obtained in glycerol/water system at gyration speeds of 58.18 rpm, 87.27 rpm, 116.36 rpm and 145.45 rpm was 26.34 sec, 15.97 sec, 9.8 sec and 6.26 sec respectively. The distribution of the SiC particulates obtained from simulation was compared with stir casting simulations. The homogeneous distribution of particulates was observed in the gyro casting simulation.

Lightweight aluminium metal matrix composite materials hold potential requisite for modern tribological applications due to its inherent and better wear resistant properties over monolithic metallic materials. This study emphasised on the development of Al based metal matrix composite with SiCp as a reinforcement and magnesium (Mg) as a wetting agent using hybrid stir casting process. The study further analysed the effects of different size variations of silicon carbide particles such as the coarse particle size, fine particle size, intermediate particle size and mixed particle size in the fabrication of the composites on the hardness and wear properties. The pin-on-disc test was also done at room temperature in a dry sliding wear condition. It was observed that the mixed particle size SiCp in composite exhibited superior hardness with the value of 98.2 compared to other particle sizes of SiCp. This is due to the fact that mixed particle size supports a greater fraction of applied load while the fine and intermediate particle sizes sustain the hardening due to dislocation. The multiple particle size reinforced composite exhibits better performance than the single particle size in terms of wear resistance as the wear rate was the lowest with the value of 0.99 X 10-5. It can be concluded that the Mg addition in the composite showed better and tailored properties with a mixed particle size of SiCp of aluminium metal matrix composite.

Graphene possesses remarkable mechanical properties and is also the lightest and strongest material known to man. Its unique optical and thermal properties, along with the fact that it is a carbon allotrope, make it ideal filler for the production of multipurpose composites, especially metal matrix composites. Due to lightweight, resilience to corrosion and low cost, aluminum is a widely utilized metal in many different industries. In this study, we aim to use the stir casting method to synthesize aluminum metal matrix composite strengthened with graphene nano filler and its characterization for mechanical properties. The strength of composite was assessed in terms of hardness and tensile strength. The composite displayed higher hardness and strength with rest to its counter-part as cast alloy. The improvement in hardness and strength may be attributed to the presence nano filler in the matrix and their uniform dispersion which brought various strengthening mechanism in to picture and increased mechanical properties.

Aluminium based composites are extensively used in various applications because of its excellent properties. Aluminium alloy (AA7075) matrix reinforced with Molybdenum disulfide (MoS 2 ) and Aluminium Nitride (AlN) have been developed via stir casting (SC) method. The mechanical properties such as hardness, tensile strength (TS) and compressive strength (CS) have been studied and reported. The increase in amount of AlN in the matrix improved the properties and decreased the elongation. The porosity % is high for the increase in quantity of the reinforcement particles.

In this present experimental study, the effect and advancement of machining parameters on cutting speed (CS) in wire electrical discharge machining (WEDM) operations were studied. The hybrid metal matrix composite (MMC) was manufactured by process named as stir casting utilizing particulates of Silicon carbide and graphite each in Al6061 combination. The analyses were outlined with response surface methodology. WEDM parameters resemble Pulse on time, current, Pulse off time and control speed are considered. The optimized parameters are Pulse on time (Level 3), Pulse off time (Level 1), peak current (Level 2) and control speed (Level 2) are the best combination to achieve best material removal rate. Pulse off time, control speed, Pulse on time and discharge current have considerable effect and most influenced control parameters on CS.

This study aims to refine a rheo-stir casting method for producing aluminium alloy 6063-based metal matrix composite reinforced with tungsten carbide at varying concentrations ranging from 0.2% to 1% by weight. AA6063/0.6WC composite was subjected to additional testing, and this shows how operations, including solution heat treatment and rolling under different circumstances, impacted the material. A closer look at the microstructure reveals that the pining effect caused by the integration of WC into the AA6063 matrix resulted in grain refinement. As the amount of increasing WC addition, the material’s mechanical characteristics enhanced. The composite with 1 wt.% WC exhibited the maximum microhardness (98 Hv), Ultimate tensile strength (UTS) (235 MPa) and Yield strength (YS) (210 MPa) due to the dispersion strengthening mechanism. The densification and particle dispersion of AA6063/WC composites were greatly improved by the rheo stir casting method. Hardness was improved by precipitation hardening after the secondary phases were dissolved in a homogenization procedure. Because dynamic recovery was inhibited during cryo-rolling, the resulting specimen had the maximum hardness of 178 Hv among all rolling techniques while being 80% thinner. It was shown that experimental YS was greater than theoretical YS after accounting for the impact of the strengthening processes.

Aluminum Metal Matrix Composites (AMMCs) are well known for their superior mechanical properties and wear resistance, which makes them suitable for use in automobiles and the aerospace industry. Wear behavior, tensile strength and micro-Vickers hardness of Al 6061 reinforced with ZrB₂, produced by the stir casting process, were studied in this research. To further improve its characteristics, the composite was subjected to T4 heat treatment, consisting of solutionizing, quenching, and natural aging. Experimental findings indicated noticeable improvements in tensile strength, hardness as well as wear resistance with higher ZrB2 content. The increased hardness is due to strong interfacial bonding between Al 6061 matrix and ZrB2 particles and precipitation hardening effect due to T4 treatment. Additionally, the homogeneous dispersion of ZrB2 particles efficiently resisted material loss during wear. The results indicate that Al 6061/ZrB2 composites, especially T4-treated ones, highly suitable for applications requiring superior surface hardness and durability.